2nd gear fix

[jesmed]

I have a '65 CP77 (engine #E1002355) with a 2nd gear that pops in/out of engagement. I can minimize the problem by using less clutch when upshifting from first to second, and going easy on throttle in second, but eventually I'd like to fix it.

Bill Silver's book says this was due to a shift fork design problem that Honda fixed with a redesigned shift fork. My questions are:

1. I don't want to have to pull the engine. Can I attempt repair upside down, by removing bottom cover/oil pan? I think I read a while ago on this forum that it could be done that way but don't remember who said so. True or not?

2. Where can I get the "redesigned" shift fork that was supposed to solve this problem?

3. Should I have other new parts on hand to install besides the shift fork when I open the tranny up? If so, which parts?

[LOUD MOUSE]

Bad news. You will have to pull the engine. To get to the trans you need to remove many parts and to remove the bottom will require you to remove both side covers and the clutch. When you remove the bottom you will need to have the engine up-side-down so you can remove the trans parts and the shift forks and drum. I've worked on many of these trans and have yet to see any change for the shift forks. What I find is warn dogs on the gears, warn shift drum point, worn shift roller, worn kick starter shaft. worn 14mm brass bushing and/or worn shift fork. I've seen many suggestions that the shift fork could be bent. I've yet to find a bent one but I have found many with the tips/ends worn down/out. I think you should get the trans and shift drum parts out and then get any/all parts you need. ..............lm

I have a '65 CP77 (engine #E1002355) with a 2nd gear that pops in/out of engagement. I can minimize the problem by using less clutch when upshifting from first to second, and going easy on throttle in second, but eventually I'd like to fix it.

Bill Silver's book says this was due to a shift fork design problem that Honda fixed with a redesigned shift fork. My questions are:

1. I don't want to have to pull the engine. Can I attempt repair upside down, by removing bottom cover/oil pan? I think I read a while ago on this forum that it could be done that way but don't remember who said so. True or not?

2. Where can I get the "redesigned" shift fork that was supposed to solve this problem?

3. Should I have other new parts on hand to install besides the shift fork when I open the tranny up? If so, which parts?

[jesmed]

LM, thanks for the speedy answers. I guess there's no easy way to do this. I tried to go refresh my memory and find what I thought I read in Bill Silver about a shift fork redesign, but couldn't find it. If you say there was no redesign, then there was no redesign! I must have mis-remembered, and it wouldn't be the first time!

[LOUD MOUSE]

May be you recall the modified Gear Cotters. Ya still need to get in there. ..............lm

LM, thanks for the speedy answers. I guess there's no easy way to do this. I tried to go refresh my memory and find what I thought I read in Bill Silver about a shift fork redesign, but couldn't find it. If you say there was no redesign, then there was no redesign! I must have mis-remembered, and it wouldn't be the first time!

[jesmed]

OK, well, maybe that's a project for next winter. Right now I'm trying to ride it, not hide it!